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At Presto  we understand how  high end audio design  combines technology and aesthetics to achieve the desired end product. Presto  have the expertise and specialism  required to produce consistent parts that are  required for the high end audio market.  We take responsibility for all aspects of your machining  from submission of the drawing to on time delivery of your components with a pristine finish.

We offer a range of finishes and the application of the product usually determines the choice of finish.  For visible Precision Machined Audio Components  where appearance is key, aluminium lends itself to stylish finishes such as anodising and wet paint. At Presto we take the dimensional accuracy and visible finish of our parts very seriously. When it comes to visible parts they are 100% checked prior to and after the finishing process.

We pride ourselves on the relationships that we’ve built with our customers. They tell us that our attention to detail is ‘second to none’. Whatever your requirements  we work with you to find the best solution for your hight end audio product.

Could Presto’s expertise help you?
If you’d like to find out more about Presto Engineering contact us to discuss  your  precision engineering requirements.
01865 883508        sales@prestoeng.co.uk

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Aluminium History

Aluminium is the most widespread metal on Earth, making up more than 8% of the Earth’s core mass. It’s also the third most common chemical element on our planet after oxygen and silicon. The Persians made extra strong pots from clay containing aluminium oxide, dating back to 5300BC. The ancient Greeks and Romans used alum in medicine as an astringent and in dyeing processes. But  Aluminium does not occur naturally in its purest form. It wasn’t until the 19^th Century  with the developments in chemistry and the advent of electricity that aluminium was discovered. It is generally found  in minerals and compounds such as feldspar, beryl, cryolite, and turquoise.The primary raw material for aluminium production is  Bauxite. Bauxite is generally  found in topsoil located in various tropical and subtropical regions, reserves are most abudant  in Africa, Oceania and South America.

In the first stage of aluminium production bauxite is processed into alumina, or aluminium oxide. Alumina looks like white powder and it is then processed into aluminium at aluminium smelters using electrolytic reduction. Aluminium ingots are produced in various shapes and sizes depending on their end use. They may be rolled into plate, sheet, foil, bars or rods.

Aluminium Smelting

Benefits

Lightweight

A known lightweight metal, it has a specific weight of approximately 2.71 g/cm3. It’s about a third of the weight of steel, which makes it easier and cheaper to transport than most other metals. The strength of aluminium can be adapted using varying alloying elements to provide better benefits including higher strength or easier formability.

Corosion Resistance

Aluminium is a corrosion resistant metal that naturally generates a protective coating. The coating formed is extremely thin and is generated when aluminium comes into contact with an oxidising environment. This protective aluminium oxide layer helps protect the surface of the metal from corrosion. Additionally, getting surface treatment such as painting or anodising can further improve the overall corrosion resistance of the metal.

Electrical and Thermal Conductivity

It is an excellent conductor of heat and electricity. Although aluminium is not as conductive as copper  but it is approximately a third of the weight. An aluminium wire with half the weight of a copper wire would have the same amount of electrical resistance. As a result, it is the chosen material for power transmission lines. It is also an excellent conductor of heat. It is used as heatsinks in  applications such as LED lights, electrical products, computer motherboards, etc.

Reflectivity 

Another benefit of Aluminium is that it serves as a good reflector. Aluminium is used in rescue blankets and light fittings because of its ability to reflect both light and heat.

Odourless and Impermeable

Even with 0.007 mm thickness of aluminium foil, it is still impermeable and doesn’t have a substance taste or smell. This is non-toxic and often used for packaging of the sensitive products including pharmaceuticals and food.

Recyclability

Aluminium is a 100% recyclable and during the recycling process, it retains all of its original properties. It is more cost-effective to use recycled metal than prime metal out of the ground.

For more information about Presto Engineering please visit our website here and if you would like a quote or to discuss a project with us please call us on 01865 883508 or e-mail: sales@prestoeng.co.uk.

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Aluminium Finishing- At Presto we take responsibility for all aspects of your project from submission of drawing to on time delivery of your components with a pristine finish.

We offer a range of finishes and the application of the product usually determines the choice of finish.  For visible parts where appearance is key aluminium lends itself to stylish finishes such as anodising.  Durability is often a deciding factor particularly when parts are for outdoor use.  When parts will not be visible and are for indoor use they can have a range of cost effective treatments such as Surtec 650, Alochrom or Irridite.  Whatever your requirements we work with you to find the best solution for your component.

Below are a selection of finishes we offer:-

 Anodising

Anodising can only be carried out on aluminium and it is the most frequently requested finish by our customers.  It is an electrochemical process that converts the metal surface into a decorative, durable corrosion-resistant anodic oxide finish and can be dyed in a variety of colours and finishes.

Anodising is accomplished by immersing the aluminium into an acid electrolyte bath and passing an electric current through the medium.  A cathode is mounted to the inside of the anodising tank; the aluminium acts as an anode so that oxygen ions are released from the electrolyte to combine with the aluminium atoms at the surface of the part.  In brief, anodising is a matter of highly controlled oxidation which is an enhancement of a naturally occurring phenomenon.

Benefits of Anodising include:-

Durability – Most anodised products have a long life span so the finish needs to be durable.  Anodising is a reacted finish that is integrated with the underlying aluminium for total bonding and unmatched adhesion.  The anodised surface is very hard and as a result preserves and extends the life of the aluminium product.  Anodised aluminium is resistant to corrosion and well suited to a wide range of applications.

Colour Stability – The sealing process used in anodising results in your anodised part looking factory new for years.  Anodised surfaces provide good stability to ultraviolet rays, do not chip or peel and are easily replicated.

Ease of Maintenance – Scars and wear and tear from handling, installation, frequent cleaning and usage are virtually non-existent.  It is generally sufficient to clean anodised surfaces with mild soap and water to maintain the original finish although a mild abrasive cleaner can be used for more stubborn stains.

Aesthetics – Anodising offers a wide variety of colour and texture alternatives and allows the aluminium to maintain its metallic appearance.

Cost – A low initial finishing cost combined with minimal maintenance costs makes anodising excellent long term value.

Health and Safety – As the anodising process is a reinforcement of a naturally occurring oxide process, it is non-hazardous and does not produce any harmful or dangerous by-products.

Anodising Pre-Treatments

• Bead Blasting

Bead blasting is the process of removing surface deposits on metal by applying fine beads at high pressure using compressed air without damaging the surface.  It is a popular choice of finish with our customers and we have invested in new Bead Blasting and Graining equipment.

Machined aluminium parts end up with lines, swirls and etching on the surface as a result of the machining process.  To prevent these imperfections from translating through a coating or anodising the surface is always made uniform by bead blasting prior to applying the chosen finish.

The benefits of Bead Blasting include:-

Uniform Finish –A perfectly clean uniform finish is achieved on all shapes of component including 3D and curved.

Styling Options – By varying the bead size the surface finish can be altered to suit individual customer requirements.  The graining can be made coarser or finer and the finish matte or bright.

• Graining

Graining is the process of polishing ‘grit lines’ onto the surface that are uniform and directional in appearance.   It is achieved by polishing the surface with an abrasive grit belt.  The finish achieved will depend upon the coarseness of the grit used.  Graining followed by clear anodising will result in a natural finish.  This finish is particularly popular for trims and badges.

Industrial Paint Finishes 

There are two systems of industrial paint finishes for aluminium finishing; wet painting and powder coating. Both of these systems will offer a durable and corrosion proof coating, but the application of the component will determine which system is used.

• Wet Paint

Generally speaking wet painting is used where a durable high quality finish is required on visible surfaces that the end user comes into contact with. For example applications can range from machined front panels for high end audio equipment through to car bodywork. Finishes are wide and varied and range from high gloss through to matte, and there is also the ability to have soft feel rubberised and suede textures incorporated.

Wet paint is commonly applied using a spray painting method, which involves utilising an air-pressurised spray gun. The air gun is made up of three main parts; the nozzle, paint basin and air compressor.  Paint is mixed with compressed air and when the trigger is activated a fine spray is released.  Usually a coating will be applied by hand, although the process can also be automated.

• Powder Coat

Powder-coating also provides a very hard wearing and durable coating.  It is ideal for products that are subject to intense handling or products that do not require such a high quality finish.  A multitude of coatings can be specified such as satin, gloss, metallic, iridescent and matte.

Powder coat application is based on the principle of opposite electric charges being attracted to one another.  Powder particles are electrostatically charged as a result of passing through a charged spray gun and are then attracted to an earthed component. The part is then thermally cured in an oven and the result is a high resistance finish.

Screen Printing

Screen printing is used in Aluminium finishing to print text and colour graphics onto almost any component for example control panels, nameplates for machines, serial and model numbers etc.  It results in a durable print that cannot be scratched off easily and is resistant to corrosion and extremes of temperature and weather.

Anoprinting

Anoprinting is generally used for demanding applications such as industrial environments. The process of anodising opens up the pores of the aluminium, a printed dye is then introduced into the porous surface layer. The pores are then sealed, trapping the ink into the surface. It changes the chemical composition of the aluminium, forming a hardened layer which provides protection from corrosion, and increases resistance to wear and abrasion. The surface appearance is resistant to marking from fingerprints and makes for a functional and decorative label.

Laser Engraving

Laser engraving is a process  that is suitable for aluminium finishing it’s where a high heat laser beam physically removes the surface of the material by causing it to vaporise and creates a cavity.  If the metal has been pre-treated or coated, the laser will engrave away this top coating to reveal the metal finish below.  Engraving can be used to customise or personalise parts and is particularly good for high wear parts.

Laser Etching

Etching is a process where a laser beam uses high heat to melt the surface and the melted material expands and causes a raised mark.  It can be done on anodised or bare aluminium.

Laser Marking

Laser marking uses a lower power beam than laser engraving and etching and leaves the surface material intact.  It is achieved by moving a low powered beam across the surface which causes oxidation under the surface turning the material black.  The precise and repeatable nature of lasers allow for fine detail marking on small components.  Laser marking is used for identifying products for example bar codes, serial numbers and regulatory symbols.

The options for aluminium finishing are endless so please do call us on 01865 883508 or e mail us at sales@prestoeng.co.uk to discuss your project.

For more information about Presto Engineering please visit our website here and if you would like to discuss a project with us please call us on 01865 883508 or e mail Julian at sales@prestoeng.co.uk.

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UK manufacturers are used to working in competitive markets as a result of Political events at home and overseas the UK faces a period of economic uncertainty.  It looks likely businesses will see raw material and component costs rise and the challenge will be delivering the same high quality products at a price the customer will pay.  Optimising product design for manufacture and assembly is a key contributor to managing costs and gaining a competitive edge.

As a manufacturer of machined aluminium parts we encourage our customers to involve us early in the design process.  It is well known that, although design costs consume approximately 20% of the total budget for a new project, typically 80% of manufacturing costs are determined by the design of the product¹.  However, the days of product design taking place in a vacuum are long gone!   Concurrent Engineering, a method of designing and developing products, in which the different stages run simultaneously, rather than consecutively, is the key to achieving a design suitable for cost effective manufacture and assembly.  Here are a few key points to consider²:-

Simplifying the design

Reducing the number of parts increases the probability of a perfect part, and reduces costs.  Fewer fabrication and assembly steps are required which gives the opportunity to integrate processes and reduce lead times.

Standardise and use common parts and materials

To minimise the level of inventory in the system and standardise handling and assembly operations.  An example of this in action is the VW Group³ chassis system which is used across a wide range of vehicles.  Known as the Modular Transverse Matrix (MQB)⁴ it is the standardisation of vehicle components and production processes and enables different models and brands to run on the same assembly line.

Design for ease of fabrication

Select materials compatible with production processes.  Working closely with Procurement colleagues can result in optimum material selection and sourcing at the best price.  Design for ease of fixturing and avoid unnecessary part features that involve extra processing effort and/or more complex tooling.

Design for easy and ‘mistake-proof’ assembly

By ensuring that the assembly process is unambiguous.  The ideal scenario is components that can only be assembled one way!  Threaded fasteners such as screws, nuts and bolts are time consuming to assemble and difficult to automate.  It is worth considering the use ‘snap-fit’ attachment methods.

Design for automated production

By ensuring that the product is easily assembled manually.  Automated production is less flexible and considerations vary depending on whether flexible robotic assembly or high speed automation is to be used.

As usual we would love to hear what you think?  Are you working closely with your designers?  Have your raw material and component costs risen since Brexit?  Please give us a call on 01865 883508 or e mail us at sales@prestoeng.co.uk.

For more information about Presto Engineering please visit our website here and if you would like to discuss a project with us please call us on 01865 883508 or e mail Julian at sales@prestoeng.co.uk.

References   

¹Claudio Favi, Michele Germani, Marco Mandolim, 2016. Design for Manufacturing and Assembly vs. Design to cost: toward a multi-objective approach for decision-making strategies during conceptual design of complex products. [pdf] Available at: http://ac.els-cdn.com/S2212827116305741/1-s2.0-S2212827116305741-main.pdf?_tid=18f28f0a-ed44-11e6-a391-00000aab0f27&acdnat=1486478921_9a20816b1f8c938f9ffd5d9556be447f [Accessed 8 February 2017].

²NPD Solutions, 2014. Design for Manufacturability/Assembly Guidelines. [online] Available at: http://www.npd-solutions.com/dfmguidelines.html [Accessed 8 February 2017].

³Dr James Moultrie, University of Cambridge, 2015. A holistic view of design for manufacture [pdf] Available at:

http://www.ifm.eng.cam.ac.uk/uploads/News/2012/15_Feb_Design_Icons_event_comes_to_IfM/DfMevent15-2-12.pdf [Accessed 8 February 2017].

⁴Volkswagen UK, 2016. Modular Transverse Matrix MQB [online] Available at http://www.volkswagen.co.uk/technology/modular-transverse-matrix-mqb [Accessed 8 February 2017]

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Example of an extruded electronics casing manufactured by Presto Engineering.What are the benefits of Aluminium extrusion?

There are many benefits of using Aluminium extrusions these being some of the main ones.

1. Low tooling costs and short lead times.
2. The ability to reduce the number of components and cost in an assembly by using features such as clip fits, screw ports and PCB location grooves.
3. Once the tooling costs are covered the shape of the section is effectively free of charge, as you only pay for the material used.
4. Inherent excellent corrosion resistance means components have a long life span.
5. If aesthetics are important and finishing is required there are a range of options from polishing, bead blasting and brushing through to anodising and painting.
6. Inherent high thermal conductivity so ideal for heat loss applications such as heatsinks.
7. Good ductility and low melting point make Aluminium easy to work with, and able to be extruded into open, semi closed and closed profiles.
8. High strength to weight ratio which can be adjusted with the use of alloys to give the strength of steel with only one third the weight.
9. Environmentally friendly as end of life components can be 100% recycled.
10. Extrusions can be easily machined or worked using a variety of methods.

Some common applications.

• Building Industry.

– Profiles used in doors, windows, cladding, guttering roofing and skylights.

• Transportation.

-More than a quarter of Aluminium produced is used in the Transportation                                    industry. Originally used for its light weight in aerospace it is now widely used in                      cars, buses, lorries, trains, motorcycles and bicycles.

• Consumer applications.

-Sports equipment, cases, chassis and heatsinks for electronics equipment,                                 furniture.

Example of an Aluminium Panel manufactured by Presto Engineering

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Wet paint

Wet painting is used where durable high quality finishes are required on visible surfaces that the end user comes into contact with. For instance applications can range from machined front panels for high end audio equipment through to car bodywork. Finishes are wide and varied and range from high gloss through to matte. There is also the ability to have soft feel rubberised and suede textures incorporated.

Wet paint is commonly applied using a spray painting method, which involves utilising an air-pressurised spray gun. The air gun is made up of three main parts; the nozzle, paint basin and air compressor. Paint is mixed with compressed air releasing a fine spray from the nozzle, upon the trigger being activated. Usually a coating will be applied by hand, although such operations can also be automated.

Powder coat

Powder-coating also provides a very hard wearing and durable coating; ideal for products which may be subject to intense handling or generally speaking, are of a cheaper nature and do not require such a high quality finish. A multitude of coatings can be specified such as satin, gloss, metallic, iridescent and matte.

Example of a powdercoated side panel at Presto

Powder coat application is based on the principle of opposite electric charges being attracted to one an other. Powder particles are electrostatically charged as a result of passing through a charged spray gun, therefore attracting the particles towards an earthed component. The part is then cured in an oven, with the coating chemically reacting to produce long molecular chains, resulting in high resistance finish.

As with both finishes, consistency between batches of components will be easier to achieve over an anodised finish, therefore benefiting an end customer who requires a critical and dependable surface finish.

Contact Presto to discuss your requirements and the most suitable industrial paint finishes for aluminium.

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The Benefits of Anodising – Anodising enhances the natural qualities of aluminium, sulphuric anodising is an electrolytic treatment for aluminium that produces a coating of aluminium oxide. It is a process achieved by suspending the raw aluminium in a mixture of water and Sulphuric acid solution and passing a DC current through. This process increases the natural aluminium oxide coating on the surface of the metal. This coating exhibits excellent corrosion resistance and can be dyed in a variety of colours. The coating is available up to around 25 microns in thickness (beyond this thickness, hard anodising is required). Aluminium is ideally suited to anodising, although other nonferrous metals, such as magnesium and titanium, can also be anodised.

The Benefits of Anodising:

• Anodising is durable and will not flake, chip, or peel over time.
• Anodised parts are easy to maintain. Rinsing or mild soap and water cleaning usually will restore an anodized surface to its original appearance. Mild abrasive cleaners can be used for more difficult deposits.
• Colour sustainability, because of the sealing process during anodising, it helps to keep your anodised part looking factory new for years. Anodizing offers a large number of colour alternatives and minimises or eliminates colour variations.
• Anodising uses the base metal – the aluminium alloy – to create a thin, extremely strong and corrosion-resistant finish. The anodised surface is very hard and thus preserves and extends the life of the aluminium product.
• Anodising, is “recycle-neutral” with minimal use of materials such as volatile organic compounds (VOCs) and heavy metals.

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